Adhesive-backed sandpaper disc for attachment to circular saw blade to provide dynamic balancing and vibration damping and method

ABSTRACT

An adhesive-backed sandpaper disc is affixed to the side wall of a standard off-the-shelf circular saw blade having two opposed flat planar faces devoid of any recesses and surrounded by a periphery of cutting teeth. The disc is made in a generally circular shape with an abrasive affixed on one surface and a layer of adhesive provided on an opposite surface covered with a release paper to prevent contamination before use. The sandpaper disc includes a plurality of slots extending toward or to the periphery of the disc which combine with the surface of the saw blade to create recesses that permit channeling of saw dust created during cutting and sanding operations. In an alternative embodiment, the slots can spiral in an arcuate path from adjacent the center of the disc to the periphery to enhance the ability of the slots to channel saw dust radially outwardly from the disc. A plurality of holes form cylindrical recesses in conjunction with the face of the saw blade to which the disc is affixed. These recesses permit dissipation of heat from the saw blade and also provide locations where saw dust can be retained so that it does not interfere with cutting and sanding operations. The disc not only sands the sides created during cutting operations but also dampens vibrations, balances the saw blade, and reduces noise. A method of using the disc is also disclosed.

[0001] This application is a Continuation-in-Part of application Ser. No. 09/577,325 filed May 24, 2000.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to an adhesive-backed sandpaper disc for attachment to a circular saw blade. In the prior art, it is known to provide an abrasive material in some form or another on the side of a cutting blade. However, Applicants are unaware of any such device that is made in the convenient form as described herein concerning the present invention.

[0003] The following prior art is known to Applicants:

[0004] U.S. Pat. No. 118,800 to Green

[0005] U.S. Pat. No. 361,238 to Proctor

[0006] U.S. Pat. No. 479,332 to Patten

[0007] U.S. Pat. No. 484,639 to Larish

[0008] U.S. Pat. No. 1,862,103 to Stratford

[0009] U.S. Pat. No. 2,001,911 to Wooddell et al.

[0010] U.S. Pat. No. 2,770,928 to Van Ormer et al.

[0011] U.S. Pat. No. 3,043,064 to Peterson

[0012] U.S. Pat. No. 3,353,308 to Zane

[0013] U.S. Pat. No. 5,125,192 to Welsch

[0014] U.S. Pat. No. 5,197,249 to Wiand

[0015] U.S. Pat. No. 5,417,525 to Lenhart

[0016] U.S. Pat. No. 5,529,528 to Young et al.

[0017] U.S. Pat. No. 5,704,828 to Young et al.

[0018] None of the references listed above teaches the combination of features comprising the present invention including the combination of a sandpaper disc with at least one slot and having an adhesive backing covered with a release paper, designed to be removably affixed to the side surface of an existing off-the-shelf circular saw blade, and which enhances performance of a circular saw blade by providing dynamic balancing and vibration damping.

[0019] In circular saw blades, at high rotational speeds, the edges of the saw blade have a tendency to deviate from the intended cutting line. This phenomenon may be due to a variety of causes, among them:

[0020] (a) surface deformities on the blade;

[0021] (b) improper distribution of residual tension stresses in the blade;

[0022] (c) improper leveling and tensioning during previous sharpening of the blade;

[0023] (d) vibrations introduced at the arbor point by the motor of the saw (the arbor point is better known as the central hole through the blade used to couple the motor thereto);

[0024] (e) vibrations caused when the sides of the blade catch or grab the work piece being cut; and

[0025] (f) compressive stresses and imbalances due to damaged teeth at the periphery of the blade.

[0026] Some of these problems may be corrected through mechanical repair of a blade. Others are more problematic and normally result in the blade being discarded. As such, a need has developed for an apparatus and method that may be used to enhance the life of a circular saw blade by solving at least some of the problems listed above.

[0027] U.S. Pat. No. 479,332 to Patten discloses a cutting disc having a piece of sandpaper mounted on its side wall. However, Patten requires the use of a cumbersome clamping member to secure the sandpaper thereon.

[0028] Similarly, U.S. Pat. No. 484,639 to Larish shows a cutting disc having a piece of sandpaper secured on a side wall thereof. However, a cumbersome clamping mechanism is required for securement.

[0029] U.S. Pat. Nos. 5,529,528 and 5,704,828, both to Young et al., disclose a saw blade with sanding surface. The invention includes a saw having a conical configuration with an annular recess designed to receive a disc of sandpaper. This saw only works when the blade is tilted with respect to its axis of rotation. By contrast, the present invention is intended to be used in association with a standard off-the-shelf saw blade consisting of a circular saw with flat planar surfaces devoid of any recesses.

[0030] The following references were cited by the Examiner during the course of the prosecution of the parent application:

[0031] U.S. Pat. No. 1,139,817 to Smith

[0032] U.S. Pat. No. 1,269,653 to Smith

[0033] U.S. Pat. No. 2,524,323 to Lloyd-Young

[0034] U.S. Pat. No. 2,819,568 to Kasick

[0035] U.S. Pat. No. 3,754,359 to Scandaletos

[0036] U.S. Pat. No. 4,345,579 to Eichenlaub et al.

[0037] U.S. Pat. No. 4,675,975 to Kucharczyk et al.

[0038] U.S. Pat. No. 5,170,595 to Wiand

[0039] U.S. Pat. No. 5,417,525 to Lenhart

[0040] U.S. Pat. No. 5,876,274 to Hariu.

[0041] The reasons why co-applicant Messinger believed the claims as set forth in the parent application patentably distinguish from these references are set forth during the prosecution history thereof. The present invention distinguishes from the teachings of these references because none of the references taken alone or in combination teaches a device designed to be added to the side walls of a circular saw blade to provide vibration damping and dynamic balancing.

SUMMARY OF THE INVENTION

[0042] The present invention relates to an adhesive-backed sandpaper disc for attachment to a circular saw blade to provide dynamic balancing and vibration damping and the method of practicing the invention. The present invention includes the following interrelated objects, aspects and features:

[0043] (1) In a first aspect of the present invention, the inventive sandpaper disc is intended to be affixed to the side wall of a standard off-the-shelf circular saw blade having two opposed flat planar faces devoid of any recesses and surrounded by a periphery of cutting teeth.

[0044] (2) The inventive sandpaper disc consists of a piece of sandpaper preferably made in a generally circular shape and having an abrasive affixed on one surface thereof with the abrasive being provided in any one of a number of grits, as desired, from fine to coarse. It is intended that such a disc be attached to the two opposed faces of a standard circular saw blade.

[0045] (3) On a face of the disc opposite that which receives the abrasive material, a layer of adhesive is provided and a release paper is placed over the adhesive to prevent contamination before use. On the periphery of the disc, a tab is formed which includes a portion of the release paper allowing the release paper to be easily removed from the back of the sandpaper disc.

[0046] (4) The sandpaper disc includes a plurality of radially extending slots therethrough. When the disc is affixed to a face of a standard off-the-shelf circular saw blade, these slots combine with the surface of the saw blade to create recesses that permit channeling of saw dust created during cutting and sanding operations, a conduit where the saw dust can flow radially outwardly and escape from the cut being created by the saw blade. One embodiment shows the slots extending radially from an area adjacent the center of the disc to its periphery. If desired, the slots can be made in a configuration in which they spiral in an arcuate path from adjacent the center of the disc to the periphery thereof. Such a configuration, while more expensive to manufacture, enhances the ability of the slots to channel saw dust radially outwardly from the disc. In a further embodiment, the slots can be made in a configuration where they extend radially of the disc but terminate short of the periphery of the disc. In this design, the disc has an unbroken periphery completely about the circumference thereof to enhance the dynamic balancing and vibration damping characteristics thereof. The sandpaper disc also includes a plurality of holes therethrough which form cylindrical recesses in conjunction with the face of the saw blade to which the disc is affixed. These recesses allow heat from the blade to dissipate therethrough and also provide locations where saw dust can be retained so that it does not interfere with cutting and sanding operations.

[0047] (5) Centrally located on the inventive sandpaper disc is an opening formed therethrough and sized to allow receipt therethrough of a shaft to which an associated circular saw blade is affixed.

[0048] It is a primary object of the present invention to provide an adhesive-backed disc designed to be affixed to the side wall of a circular saw blade to provide dynamic balancing of a circular saw blade while also providing a vibration damping characteristic.

[0049] Accordingly, it is a first object of the present invention to provide an adhesive-backed sandpaper disc for attachment to a circular saw blade.

[0050] It is a further object of the present invention to provide such a sandpaper disc designed to be affixed to a circular saw blade that has flat side surfaces, each of which lies in a single plane, which disc sands the work piece while sawing operations are taking place.

[0051] It is a still further object of the present invention to provide such a sandpaper disc designed to be affixed to a side face of a circular saw blade that is devoid of any recesses.

[0052] It is a yet further object of the present invention to provide such a sandpaper disc made of a size that can be applied to any standard circular saw blade typically used by handymen, craftsmen, and carpenters.

[0053] It is a still further object of the present invention to provide such a device wherein the vibration damping also causes a reduction of noise caused by vibrations.

[0054] It is a yet further object of the present invention to provide such a sandpaper disc having recesses extending radially outwardly therefrom.

[0055] It is a still further object of the present invention to provide such a sandpaper disc having slots extending outwardly therefrom in a spiral configuration.

[0056] It is a yet further object of the present invention to provide such a sandpaper disc with a plurality of holes therethrough providing recesses to receive saw dust and to channel or release heat radiating from the saw blade.

[0057] These and other objects, aspects and features of the present invention will be better understood from the following detailed description of the preferred embodiments when read in conjunction with the appended drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0058]FIG. 1 shows an off-the-shelf standard circular saw blade having a first embodiment of the present invention affixed to a side surface thereof.

[0059]FIG. 2 shows a sandpaper disc made in accordance with the teachings of the present invention with a tab connected to release paper affixed thereto.

[0060]FIG. 3 shows a cross-sectional view along the line 3-3 of FIG. 2.

[0061]FIG. 4 shows a second embodiment of a sandpaper disc in accordance with the teachings of the present invention.

[0062]FIG. 5 shows a third embodiment of a sandpaper disc in accordance with the teachings of the present invention.

SPECIFIC DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0063] Before referring to the drawing figures, the following characteristics are common to all of the embodiments of the present invention. Each sanding disc disclosed herein consists of an abrasive mineral, a backing onto which the abrasive mineral is applied, and an adhesive bond. Backings are the base for the abrasive minerals and combined with the adhesive bond support and anchor the abrasive mineral in place. The backings may comprise a number of different materials including paper or cloth. The weight of the backing material is specifically designed to enhance the balancing feature as well as the sanding feature and are selected for their elasticity, flexibility, strength and durability.

[0064] An adhesive bonding system is required to secure the abrasive mineral to the backing. In the present invention, it is contemplated that a two stage process will be applied utilizing two coats of adhesive that anchor the abrasive mineral while providing enhanced physical strength to the finished product.

[0065] The discs disclosed herein employ a pressure sensitive ago adhesive to adhere the disc to the side wall of a circular saw blade. Such an adhesive provides the most flexible bond possible as a disc is being adhered to the side of the circular saw blade.

[0066] With reference, first, to FIG. 1, a circular saw blade is generally designated by the reference numeral 1 and is seen to include a face 2 as well as an opposite face (not shown) that lies in a plane parallel to the plane in which the face 2 lies. The faces of the blade 1 are flat and, as explained above, each lie in a single plane. At the center of the disc 1, an opening 3 is provided that is sized to receive a shaft to which it may be affixed on a circular saw machine (not shown). The periphery of the disc 1 has a plurality of teeth 4 as is well known. The surfaces of the circular saw blade 1 including the surface 2 shown in FIG. 1 are devoid of any recesses or other treatments specifically provided to receive a sandpaper disc. The blade 1 preferably consists of a standard off-the-shelf circular saw blade.

[0067] With reference, now, to FIGS. 2 and 3, the present invention is generally designated by the reference numeral 10 and is seen to include a sandpaper disc 11 having a generally circular periphery 13 and, with reference to FIG. 3, having a back surface covered with an adhesive material 15. A piece of release paper 17 covers the adhesive 15 and includes a tab 19 allowing the release paper 17 to be gripped and easily removed from the adhesive 15 of the disc 11. As seen in FIG. 3, the tab 19 may also include a portion of the disc 11 although, during manufacture, a cut 23 is formed between the portion 21 and the disc 11 allowing the portion 21 to form a part of the tab 19 allowing easy removal of the release paper 17.

[0068] The disc 11 includes a surface 25 that is covered with an abrasive material having a grit that may be of any desired degree from coarse to fine as is well known to those skilled in the art. If desired, the coarseness or fineness of the grit of the abrasive surface may be consistent throughout the face 25 of the disc 11 or may vary from one portion to another either radially or circumferentially. The abrasive material may, if desired, comprise sand.

[0069] With further reference to FIG. 2, the disc 11 has a plurality of slots 27 extending radially outwardly from adjacent the center thereof. When the disc 11 is affixed to a surface such as the surface 2 of a standard off-the-shelf circular saw blade 1, the surface 2 of the blade 1 combines with each slot 27 to form a recess that allows channeling of saw dust created during sawing operations radially outwardly from the disc 11 and the blade 1.

[0070] Additionally, the disc 11 has an opening 29 centrally formed therethrough and designed to surround the opening 3 in the blade 1 (FIG. 1) so that affixing of the disc 11 on the surface 2 of the blade 1 will do nothing to impede a shaft (not shown) of a circular saw machine (not shown) from being inserted through the opening 3 in the blade 1 when the blade 1 is being affixed thereto.

[0071] With further reference to FIGS. 1 and 2, it is seen that the disc 11 also includes a plurality of holes 31 extending therethrough. When the disc 11 is affixed on a side surface of a circular saw blade such as the surface 2 depicted in FIG. 1, the holes 31 combine with the surface 2 to create cylindrical recesses that receive saw dust during cutting and sanding operations to prevent the saw dust from impeding operation of the saw blade 1 and the disc 11. The holes 31 also provide channels facilitating dissipation of heat radiating from the saw blade.

[0072] Reference is now made to FIG. 4 which depicts an alternative embodiment of the inventive disc designated by the reference numeral 40. In the alternative embodiment 40, like elements are depicted using like primed reference numerals. The disc 40 differs from the disc 11 in that the disc 40 includes slots 41 that spiral outwardly from their innermost terminations 43 to their peripheral openings 45. The slots 41 spiral in a direction such that when the disc 40 is rotating in the clockwise direction in the view of FIG. 4, the spiral nature of the slots 41 enhances the efficiency of channeling of saw dust outwardly and away from the disc 1 and the disc 40.

[0073] Reference is now made to FIG. 5 which shows an alternative embodiment of the present invention. In FIG. 5, the disc is generally designated by the reference numeral 50 and is seen to include a circular periphery 51 and a surface 53 covered with an abrasive material. The back surface is not shown in detail in FIG. 5 but corresponds to the back surface for the embodiments best illustrated in FIGS. 2, 3 and 4. A central hole 55 permits alignment with the central hole through a circular saw blade. Slots 57, 59 and 61 are provided, although any desired number of slots may be provided so long as they are equally spaced about the circumference of the disc 50. In the embodiment of FIG. 5, it is important to note that the slots 57, 59 and 61, while extending all the way through the base of the disc 50, do not extend completely out to the periphery 51 thereof. Through this design, the periphery of the disc 50 is completely unbroken, unlike the periphery of the embodiments of FIGS. 2 and 4 which is broken at the four locations where the slots thereof peripherally terminate. In the embodiment of FIG. 5, this unbroken periphery enhances the strength of the disc 50 and enhances its ability to damp vibrations and balance a circular saw blade to which it is affixed. The slots 57, 59 and 61 still provide the function of allowing the channeling of saw dust. Although the slots 57, 59 and 61 do not extend through the periphery of the disc 50, they are able to perform this function at least providing a location where saw dust may be temporarily stored. The slots also provide a cooling function by exposing the areas of the circular saw blade aligned therewith to the atmosphere to allow heat to dissipate. Holes 63 are dispersed uniformly about the periphery of the disc 50 and perform the same functions described above concerning the embodiments of FIGS. 2 and 4, namely, providing recesses for the channeling of saw dust as well as open areas to allow dissipation of heat from the circular saw blade.

[0074] Due to the physical characteristics of the materials used in balancing and vibration damping sanding discs and concerning their adhesive attachment to the side walls of circular saw blades, the objectives of the present invention are effectively met.

[0075] The elasticity of the adhesives used, the flexibility of the backing materials, the porosity of the materials, all combine to absorb vibrations and stiffen the circular saw blade when the inventive discs are affixed thereto. Noise is reduced as explained above through vibration damping and friction created during cutting operations is reduced since the blade is less likely to flex with the disc or discs affixed thereto. Additionally, tensile stresses around the periphery of the blade are reduced along with compressive stresses at the center of the blade.

[0076] The vibration damping, balancing, and noise abatement features of the present invention apply not only to the embodiment of FIG. 5 but to the embodiments of FIGS. 2 and 4 as well.

[0077] Various modifications and alterations in the embodiment shown may be contemplated by those skilled in the art. For example, either more or fewer slots 27 or 41 may be provided in the disc 11 or 40. Furthermore, any desirable abrasive material may be employed on the surface of each disc as desired. Furthermore, the holes 31 or 31′ may be omitted if desired or more or fewer such holes may be provided. Furthermore, the periphery of the inventive disc 11 or 40 does not necessarily have to be circular. The only requirement is that it is appropriately sized to securely fit on the side surface, for example, as designated by reference numeral 2 in FIG. 1 of a circular saw blade such as that which is designated by the reference numeral 1. Of course, a circular periphery 13 or 13′ is preferable since it provides uniform abrasive material throughout the periphery of the associated saw blade 1.

[0078] In practicing the method of the present invention, a disc such as is described with reference to FIGS. 2, 4 or 5 is provided having all of the structures and features thereof. That disc is adhesively secured to the side wall of a circular saw blade with another corresponding disc affixed to the other side of the circular saw blade. In the present invention, the circular saw blade to which the inventive discs are affixed consists of a circular saw blade having flat faces lying in parallel planes. With the discs so affixed to the side walls of the circular saw blade, the circular saw blade is activated to cut a work piece while the discs provide the functions of sanding the cut faces of the cut formed by the circular saw blade while damping vibrations balancing the saw blade and reducing the noise emitted therefrom.

[0079] As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfill each and every one of the objects of the invention as set forth hereinabove and provide a new and useful adhesive-backed sandpaper disc for attachment to circular saw blade of great novelty and utility.

[0080] Of course, various changes, modifications and alterations in the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof.

[0081] As such, it is intended that the present invention only be limited by the terms of the appended claims. 

1. In a circular saw blade having a generally circular configuration with a central mounting hole and flat side faces lying in parallel planes, and a periphery having a multiplicity of circumferentially disposed teeth, the improvement comprising an abrasive disc releasably attachable to one of said side faces of said blade, said disc including: a) a first surface covered with an abrasive material; b) a second surface opposite said first surface and covered with an adhesive; c) said disc including a plurality of slots each extending from a location within said disc and toward a periphery of said disc, each slot extending completely through said first and second surfaces of said disc; and d) a plurality of holes through said disc, each of which exposes a portion of a flat side face of said blade (1) to permit heat emanating from said flat side face of said blade to radiate through said disc, and (2) to provide a recess for receipt of dust particles generated by rotation of said blade through a piece of material being cut thereby, said disc damping vibrations and balancing said blade.
 2. The improvement of claim 1, wherein said abrasive material comprises sand.
 3. The improvement of claim 1, wherein said slots terminate radially inwardly of said periphery of said disc.
 4. The improvement of claim 3, wherein said plurality of slots comprises three slots.
 5. The improvement of claim 3, wherein said plurality of slots comprises four slots.
 6. The improvement of claim 1, wherein said slots extend to the periphery of said disc.
 7. The improvement of claim 1, wherein said plurality of holes comprises at least one hole between adjacent slots.
 8. A method of damping vibrations and balancing a circular saw blade, said circular saw blade including a periphery with a plurality of teeth and side walls consisting of flat surfaces lying in parallel planes, the method including the steps of: a) providing an abrasive disc having a first surface covered with an abrasive material and a second surface opposite said first surface and covered with an adhesive; b) providing said second surface with a release paper covering said adhesive; c) providing said disc with a plurality of slots equally spaced about a periphery of said disc and each slot extending from a location within said disc adjacent a center thereof and extending radially toward said periphery, each slot extending completely through said first and second surfaces of said disc; d) providing said disc with a plurality of holes; e) removing said release paper; f) affixing said disc onto one of said side walls of said circular saw blade.
 9. The method of claim 8, wherein said slots terminate radially inwardly of said periphery of said disc.
 10. The method of claim 8, wherein said plurality of holes comprises at least one hole between adjacent slots.
 11. The method of claim 8, wherein each of said slots extends to said periphery of said disc.
 12. The method of claim 8, wherein said plurality of holes consists of at least two holes between adjacent slots.
 13. The method of claim 8, further including the step of providing said disc with a central hole alignable with a central hole on said blade. 